3-D Continuous Shaping Of Edible-Based Extrudates

ABSTRACT

A chew toy of non-uniform shape may be manufactured from an edible starch composition by introducing said composition to an extruder having a barrel and subjecting the composition to shear and heat to form a melt, and conveying the melt through an adjustable orifice while varying the cross-section dimensions of the orifice to form an extrudate having thickness dimensions that varies along its length. This may be followed by cutting the extrudate to length. The extrudate may also be passed between cooperating cavities and formed to shape. The extrudate may also be guided into predetermined patterns by repositioning the die relative to a molding surface.

FIELD OF THE INVENTION

This invention relates to a method of extruding edible compositions withutility in the form of three dimensional edible products for an animalor as a chew toy for a pet. The manufacturing method disclosed hereinemploys melt mixing of an edible resin with selected amounts ofadditives, including water and other fillers, followed by extrusionwherein during or directly following extrusion the extrudate may beformed into a selected three dimensional shape which may be non-uniform.The processing conditions, including barrel temperatures and coolingprofiles may be adjusted along with the relative amounts of additivesand water present to provide the ability to produce extruded shapes thatmay obviate the need for more traditional forming procedures, such asinjection molding.

BACKGROUND

The prior art does provide various disclosures directed at convertingvarious resins such as starch or related materials into an injectionmolded or shaped article. For example, there are disclosures pertainingto the development of edible animal chews that are digestible and/ornutritious along with a texture that can be individually adjusted tosuit a wide variety of a dog's preferences or needs. Attention istherefore directed to the following exemplary disclosures: U.S. Pat. No.6,180,161 “Heat Modifiable Edible Dog Chew”; U.S. Pat. No. 6,159,516“Method of Molding Edible Starch”; U.S. Pat. No. 6,126,978 “Edible DogChew”; U.S. Pat. No. 6,110,521 “Wheat and Casein Dog Chew withModifiable Texture”; U.S. Pat. No. 6,093,441 “Heat Modifiable Peanut DogChew”; U.S. Pat. No. 6,093,427 “Vegetable Based Dog Chew”; U.S. Pat. No.6,086,940 “High Starch Content Dog Chew”; U.S. Pat. No. 6,067,941“Animal Chew”; U.S. Pat. No. 6,056,991 “Turkey and Rice Dog Chew WithModifiable Texture”; U.S. Pat. No. 5,941,197 “Carrot Based Dog Chew”;U.S. Pat. No. 5,827,565 “Process for Making an Edible Dog Chew”; U.S.Pat. No. 5,339,771 “Animal Chew Toy Containing Animal Meal”; U.S. Pat.No. 5,240,720 “Dog Chew with Modifiable Texture”; U.S. Pat. No.5,200,212 “Dog Chew with Modifiable Texture.” Attention is also directedto U.S. Pat. No. 6,165,474 entitled “Application for Patent forNutriceutical Toy”, U.S. Pat. No. 5,419,283 entitled “Animal Chew Toy ofStarch Material and Degradable Ethylene Copolymer”, U.S. ApplicationPublication No. 2004/0009268 entitled “Blends Of Starch AndAliphatic-Aromatic Based Polyester Resins” and U.S. ApplicationPublication No. 2007/0031555 entitled “Direct Starch Molding”.

A variety of efforts have been considered to convert starch, withminimum degradation, into an injection molded product of a desiredconfiguration. Such efforts have focused on the use of propylene glycol,fatty acid esters, alkali salts of protein material and/or water as astarch additive, followed by melt processing techniques such asextrusion and/or injection molding. The cited art generally is directedat extruding a product having uniform dimensions and injection moldingthat extruded composition to form more complex three dimensional shapes.A need exists for shaped articles that can be produced by extrusionalone and not incur the expense of matched tooling or the associatedrelatively slower injection molding process.

Accordingly, the present invention is directed at formulating ediblecompositions for an animal, along with selected processing/moldingprofiles, which formulations and processing/molding profiles allow forthe continuous formation of an edible-based animal chew toy of a desiredshape. In addition, it is also an object of this invention to provide anumber of processing devices or protocols which may be used in acontinuous extrusion process to produce a non-uniform, three dimensionalshape product for consumption by an animal.

SUMMARY

In a first exemplary embodiment, the present disclosure relates to amethod for forming chew toys of selected shape from an ediblecomposition by extrusion, comprising the steps of providing an extruderincluding a barrel and a die having an adjustable orifice capable ofproviding a variety of cross-sectional dimensions and providing anextrudable composition comprising edible resin and water. This may thenbe followed by introducing the composition to the barrel and subjectingthe composition to shear and heat to form a melt and conveying the meltthrough said orifice while varying the cross-section dimensions of theorifice to form an extrudate having thickness dimensions that vary alongits length. The water content of the composition is sufficient toprovide that the composition can be varied in cross-section whenconveyed through the orifice with variations in the orificecross-sectional dimension.

In another exemplary embodiment, the present disclosure relates tomethod for forming chew toys of selected shape from edible compositionsby extrusion, comprising the steps of providing a first extruder, asecond extruder and a third extruder, wherein the first extruderincludes a first profile die, the second extruder includes a secondprofile die and the third extruder includes a third profile die. Thismay then be followed by providing a first edible composition to thefirst extruder and a second composition to the second extruder and athird composition to the third extruder and processing the first andsecond compositions through the first and second extruders includingthrough the first and second profile dies to form first and secondextrudates. Such extrudates may then be joined to one another in ashaping die, the shaping die having an opening substantially the sameshape as the combined shapes of the first and second profile dies. Thismay then be followed by processing the third composition through thethird extruder including through the third profile die to form a thirdextrudate and intermittently joining the third extrudate with thecombined first and second extrudates in a second shaping die, the secondshaping die having an opening substantially the same shape as thecombined shapes of the first and second and third profile dies.

In a still further embodiment, the present disclosure relates to amethod for forming chew toys of selected shape from edible compositionsby extrusion, comprising the steps of providing an extruder including abarrel and a die and providing an extrudable composition comprisingedible resin and water. The composition may then be introduced thebarrel along with subjecting the composition to shear and heat to form amelt and conveying said melt through said die to form an extrudate andpassing the extrudate between cooperating mold cavities havingcomplementary shapes which form the shape of the chew toy while saidextrudate is at a temperature and moisture level which allows theextrudate to form within said cooperating mold cavities. This may thenbe followed by forming the extrudate into the shape of a chew toy.

In another exemplary embodiment, the present disclosure is directed at amethod for forming chew toys of selected shape from edible compositionsby extrusion, comprising the steps of providing an extruder including abarrel and a die and providing an extrudable composition comprisingedible resin and water. This may be followed by introducing thecomposition to the barrel and subjecting the composition to shear andheat to form a melt and conveying the melt through the die to form anextrudate. One may then provide a surface to receive the extrudate andguide the die over the surface in a predetermined pattern to positionthe extrudate on the surface in the predetermined pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the present disclosure are set forth hereinby description of embodiments consistent with the present disclosure,which description should be considered in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a schematic sectional view of an exemplary extruder, accordingto the present disclosure.

FIG. 2 is a side view of an exemplary dog chew, according to the presentdisclosure.

FIG. 3 is an end view of the dog chew of FIG. 2.

FIG. 4 is a front view of a first exemplary embodiment of an adjustabledie for forming the dog chew of FIG. 2, including a plurality ofinteracting adjacent sliding plates spread apart to form a shapedorifice for an extrudate.

FIG. 5 is a front view of the sliding plates of FIG. 4 in a nearlyclosed-off position to provide an orifice for a connecting portionbetween chews.

FIG. 6 is a front view of another adjustable die including a flexiblering or tube that may be deformed to a desired shape by externalstroking members

FIG. 7 is a front view of another adjustable die including plates whichcooperate in a rotary manner to form an adjustable opening for anextrudate.

FIG. 8 is a front view of an adjustable extrusion die which includesadjustable protrusions that may form a portion of the periphery of thedie and be adjusted in depth to vary the shape of the die opening.

FIG. 9A is perspective view of an exemplary dog chew formed by extrudingtwo similar “comma-shaped” extrudates and combining them. FIG. 9Billustrates the addition of a third like-shaped extrudate to form athree-lobed dog chew.

FIG. 9C is perspective view of an exemplary dog chew formed by extrudingtwo similar curved extrudates and combining them. FIG. 9D illustratesthe addition of a third heart-shaped extrudate to form a different lobeddog chew.

FIG. 10 is a schematic representation of a flow chart of the process andapparatus for producing the dog chews of FIGS. 9A-9D.

FIG. 11 is a side view of an apparatus for forming an extrudate intothree dimensional dog chews using interacting wheels equipped withcooperating mold cavities.

FIG. 11A is an enlarged view of one of the mold cavities of theinteracting wheels of FIG. 11.

FIG. 12 is a side view of an apparatus for forming an extrudate intothree dimensional dog chews using interacting belts equipped withcooperating mold cavities.

FIG. 13 is a schematic view of a robotic workstation including anextruder, according to the present disclosure.

FIG. 13A is a perspective view of a different molding surface of FIG.13, including a mold cavity for a dog chew.

FIG. 14A is a perspective view of an exemplary dog chew, formed by therobotic workstation of FIG. 13.

FIG. 14B is a perspective view of another exemplary dog chew, formed bythe robotic workstation of FIG. 13.

FIG. 15 is a perspective view of another exemplary dog chew, formed by apair of rotating extrusion dies, according to the present disclosure.

DETAILED DESCRIPTION

Still other objects and advantages of the present invention will becomereadily apparent to those skilled in the art from the following detaileddescription, wherein it is shown and described preferred embodiments ofthe invention. As will be realized the invention is capable of other anddifferent embodiments, and its several details are capable ofmodification in various respects, without departing from the invention.Accordingly, the description is to be regarded as illustrative in natureand not as restrictive.

For elements common to the various embodiments of the presentdisclosure, the numerical reference character between the embodiments isheld constant, but distinguished by the alphanumeric character to theexisting reference character. In other words, for example, an elementreferenced at 10 in the first embodiment is correspondingly referencedat 10A, 10B, and so forth in subsequent embodiments. Thus, where anembodiment uses a reference character to refer to an element, thereference character applies equally, as distinguished by alphanumericcharacter, to the other embodiments where the element is common.

In accordance with the present invention, a method of manufacturingedible products is disclosed, which employs extrusion melt mixing ofedible resin with selected amounts of additives, including water andother fillers, followed shaping into three dimensional articles ofnon-uniform shape. Such shaping may take place in a die set having anadjustable opening through which the starch-based melt exits theextruder, and/or by shaping the extrudate directly downstream of the dieset with post-forming apparatus. Preferably, the products as describedherein are manufactured in the form of chew toys and other similarlyshaped products for pets.

Edible resin herein refers to a resin that is intended for ingestion anddigestion by an animal. In that regard, edible resin herein does notinclude petroleum based resin products, such as polyethylene,polypropylene and/or other polymers that are sourced directly frompetroleum by-products (e.g. from monomers that are derived frompetroleum that are subsequently polymerized). Examples of edible resinstherefore include starch, vegetable and/or vegetable protein, meat basedmaterial, etc., which are typically ingested and digested by an animal.

“Non-uniform” as used herein refers to shaped articles, such as dogchews, animal toys and the like, which do not have a profile of constantcross-section, but instead may vary in dimensions, and therefore inshape, along the length and/or width and/or height of such article. Inother words, the article may preferably vary in width and height alongits length.

Any carbohydrate of natural or vegetable origin, composed mainly ofamylose and/or amylopectin, may be used to from the edible composition,in accordance with the present disclosure. Such may be extracted fromvarious plants, such as potatoes, rice, tapioca and corn and fromcereals such as rye, oats and wheat. The starch may also be extractedfrom fruits, nuts and rhizomes, or arrowroot, guar gum, locust bean,arracacha, buckwheat, banana, barley, cassava, konjac, kudzu, oca, sago,sorghum, sweet potato, taro, yams, fava beans, lentils and peas. Thestarch, in conjunction with any other edible material or resin, may bepresent at between about 30-99% including all increments and valuestherebetween, such as levels above about 50%, 85%, etc. Particularlypreferred, however, are potato starch and corn starch flour and mixturesthereof.

The starch employed herein may be raw starch, which may be understood asstarch that has not seen a prior thermal molding history, such asextrusion or other type of melt processing step. However, the starchherein may, e.g., be heated for drying purposes, which would not amountto a prior thermal molding history. The raw starch itself may also benative, which may be understood as unmodified starch recovered in theoriginal form by extraction and not physically or chemically modified.The raw starch may also be in powder form of varying particle size,which may be understood as milled and/or pre-sifted. It should beunderstood that the raw starch may also have varying degrees moisturepresent.

The starch composition may include cellulose. The cellulose may be, forexample, a long-chain polymer of polysaccharide carbohydrate. Thecellulose may also be derived or extracted from plants. The cellulosemay be incorporated into the starch composition between about 1-15% byweight of the starch composition and any increment or valuetherebetween, including 4%, 10%, 11%, etc.

Emulsifiers or surfactants may also be incorporated into the starchcomposition. The emulsifier may be present between about 1-10% by weightof the starch composition and all increments or values therebetween,including 3%, 4%, etc. The emulsifier may include, for example,lecithin, which may be extracted or derived from, for example, egg yolkor soy beans.

The starch composition may also include a plasticizer. The plasticizermay include for example, glycerin. The plasticizer may be incorporatedbetween about 15-30%, including all increments and values therebetween,such as levels greater than 15%, 21%, 27% etc.

A humectant may also be incorporated into the starch composition. Thehumectant may include, for example, oat fiber. The humectant may beincorporated between about 0.1-5% by weight of the starch compositionincluding all intervals and values therebetween, including 1%, 25%, etc.A humectant may be understood to be any additive that may absorb waterin the material.

The edible resin (e.g. starch) composition may also include water. Thewater may be introduced into the composition at between about 1-40% byweight of the starch composition and any increment or value therebetweenin 1% increments, including e.g. 2-39%, 3-38%, etc. Preferably, thewater level is such that it is sufficient to allow for the compositionto be formed continuously in the die at temperatures the avoid resindegradation. Such preferred levels may be 10% by weight to 30% byweight, or 10% by weight to 20% by weight, or 10% by weight to 15% byweight, which then begins to approach the desired water level in thefinal product (i.e. 10% by weight to 15% by weight).

Accordingly, after the product has been formed, the water may be presentbetween 10-15% by weight of the edible (e.g. starch) compositionincluding all increments or values therebetween, such as, 10%, 11%, 12%,13%, 14% or 15% by weight. However, in accordance with the presentdisclosure, those skilled in the art will recognize that the values areonly preferred, and other levels of water may be optionally selectedwithin the broad teachings provided herein.

The edible (e.g. starch) composition may include a nutraceutical. Thenutraceutical may be fermented soya. Fermented soya nutraceuticals areavailable from Bio Food, Ltd., Pine Brook, N.J. and sold under thegeneral trademark Soynatto® The fermented soya may be present betweenabout 1-40% by weight of the starch composition, including allincrements and values therebetween, including 10%, 20%, etc.

The edible (e.g.) starch composition may also include enzymes and/orco-enzymes which are similarly available through Bio Foods, Ltd., PineBrook, N.J. and sold under the trademark of BT-CoQ10®. This reportedlyis a biologically transformed (fermented) cell mitochondrial coenzymeand contains Coenzyme Q10, antioxidants, phytonutrients and cofactormineral nutrients and other cell constituents. The enzymes and/orco-enzymes may be present between 0.1-10% by weight of the starchcomposition, including all increments and values therebetween such as1%, 5%, etc.

Other additives may be introduced into the composition as well. Theseadditives may include vegetable matter, fruit matter, rawhide, nuts, nutbits or nut flour such as peanut flour, and animal or fish products,by-products, meal or digests, etc. Glutens may also be incorporated intothe starch composition. Gluten may be understood as water-insolubleprotein complex extracted from cereal grains such as maize or corn andwheat. These additives may be present individually or cumulativelybetween about 0.1-50% by weight of the starch composition and allincrements and values therebetween, including 0.1-5.0%, 15%, 25%, etc.

Additionally, flavorants, herbs, herbal extracts, vitamins, minerals,colorants, yeast products, attractants, etc, may be incorporated intothe edible (e.g. starch) composition. Yeast products may includenutritional yeast or brewers yeast such as saccharomyces cerevisiae,dairy yeast such as kluyveromyce marxianus or wine yeast such assaccharomyces fermentati. Attractants may include compounds listedherein, such as the animal or fish digests, or other compounds that mayincrease an animal's interest in the starch composition. These additivesmay be present individually or cumulatively between about 0.01-25% byweight of the starch composition and any increment or valuetherebetween, including 0.01-0.5%, 10%, 20%, etc. The composition mayalso include calcium carbonate. The calcium carbonate may be presentbetween about 5-10%.

The edible (e.g. starch) composition may be introduced directly into thebarrel of an extruder 100, illustrated in FIG. 1, through a hopper orother feeding device 102. It is contemplated that in a preferred method,the ingredients in the starch composition may be blended together priorto introduction into the hopper, the ingredients may also be blendedinto a plurality of sub-formulations and added to the hopper, or evenintroduced individually into the hopper. Various feeding devices forintroducing the additives into the barrel may be contemplated includingloss-in weight gravimetric blenders/feeders, auger feeders, venturiloaders, etc.

Those skilled in the art will appreciate that an extruder 100 maytypically contain a barrel 104 including a feed section 106, a screw 108and an output nozzle 110. The barrel 104 may include a plurality oftemperature control zones 112, 114, 116, 118 in the barrel extendingfrom the feed section 106 to the nozzle 110. The nozzle may feed aprofile die 120, capable of being adjusted such that the orifice 122 inthe die may be adjusted in shape as the extrudate is exiting so that theextrudate may vary in shape and may cool to form animal toys or chewshaving non-uniform dimensions. The arrows adjacent the die 120 indicatethat the die may be capable of being rotated relative to the extrudate,and/or that the die orifice 122 may be opened or closed as needed tovary the profile shape and size during the extrusion process such thatthe width and thickness of the extrudate may be varied vs. the length toprovide non-uniform shapes.

“Extrudate” as used herein refers to a molten composition that is forcedthrough a shaping orifice as a continuous body and which is capable ofmaintaining the approximate shape of that orifice, unless otherwiseacted upon, until the composition cools.

Table 1 below illustrates a range of various processing parameters formanufacturing the non-uniform shaped products of the present disclosure.

TABLE 1 Comparative Extruder Parameters Throughput 50-150 kg/hr 300-600kg/hr Screw Diameter 70 mm. 72 mm. Screw Length 940 mm. 2300 mm. L/D 1332 Extruder Type single screw twin screw Initial H₂O Level 20-40% 10-15%Max. Heating Zone 300° F. 390° F.

The various heating zones in the extruder may be set at differenttemperatures so that a homogenous blend of ingredients having theability to flow under pressure can be provided as a melt to anadjustable extrusion die. By providing a temperature profile along thebarrel from feed zone to the die, combined with a given residence timeand shear rate, thermally sensitive ingredients may be included in thestarch composition without total degradation.

In addition, the melt in the barrel of the extruder may be exposed to ashear rate between the screw and the barrel of the extruder whileplasticating is taking place, and the shear rate range may be in therange of about 1 sec⁻¹ to about 5,000 sec⁻¹ and all incrementstherebetween (for instance, such as 1000 sec⁻¹, such as 900 sec⁻¹ or 800sec⁻¹ or 700 sec⁻¹, etc.).

Preferably, at least 0.1-50% of the thermally sensitive additives, suchas vitamins, minerals and herbs, remain non-degraded, most preferably atleast 75%, even more preferably at least 80-90%, and in the mostpreferred embodiment, over 90% of the thermally sensitive additives arenot thermally degraded by the molding process. This approach then allowssuch additives to be distributed in the molded chew toy of the presentdisclosure and in a preserved state such that their nutritional ortherapeutic value is maintained.

In one exemplary embodiment, the water content of the edible (e.g.starch) composition within a preconditioner (prior to extrusion) mayfirst be set in the range of about 10-40% by weight with respect to thatof the starch, which mixture may be achieved by mixing the starch withwater in a Wenger DDC Preconditioner that provides controlledpre-moisturization and complete mixing of the water with the starchmaterial. This may then be followed by placement of the starch/watercomposition into an extruder, and in that regard, preferably, a WengerTX Magnum Extruder, available from the Wenger Company. While twin-screwoperation is preferred, it is contemplated that single screw extrudersmay be used. Finally, in the context of the present disclosure, wherethe water level charged in the extruder may be preferably lowered duringthe course of extrusion, an extruder capable of venting may be employed,wherein such venting lowers the water level to a desired level. Tofacilitate such water level change, it may be preferable to apply alight vacuum to the extruder to thereby provide a more efficient removalof water from the extrudate therein.

FIG. 2 is a side view of an exemplary dog chew 10, according to thepresent disclosure including a central shaft 12 and bone-like condyles14 at each end. FIG. 3 is an end view of the dog chew of FIG. 2.Reference numeral 16 is a connecting portion which extends betweenadjacent chews as they are formed by extrusion to allow the extrudate tobe handled in continuous form and then separated into individual chewslater (for packaging, at the store, or in the home, as needed).Reference numeral 20 represents one example of how the cross-section ofthe chew may be varied in size and shape during the extrusion process.It should further be noted that the shaft 12 as shown is not of aconstant cross-section, as one might expect from an extrusion process,and that the ends 14 of the chew 10 vary even more in shape(particularly see FIG. 3). Such a dog chew may be formed by using a diefor the extrudate in which the orifice in such die may be varied indimensions as the extrudate is being forced therethrough to produce thenon-uniform shape, for example, of FIG. 2.

In a first exemplary embodiment, the orifice in the extruder die may beformed of a plurality of interacting plates, the plates each having ashaped partial opening therein, the plates capable of sliding againstone another so that the partial openings at least partially coincide andprovide a cross-section (orifice) of the desired shape (see crossedarrows in FIG. 1.). The plates may be varied in relative position toeach other so that a small connecting portion (such as 16 in FIG. 2) maybe formed, or a bulbous shape (such as condyle 14 may be formed), thepartial opening in each individual plate cooperating with the partialopenings to form a portion of the periphery of the extrudate. Further,an intermediate shaped opening (such as to form the shaft 12 of the chewof FIG. 2) may be formed. The relative positioning of the plates as theextrudate is being forced through the die allows a varied non-uniformshape, such as shown in FIG. 2, to be formed. The plates may be moved bymotorized, pneumatic or hydraulic means and the means may beprogrammable. The connecting portion may have smaller cross-sectionaldimensions than the main portion or the end portions of the chew toy,smaller meaning in the range of about 10% to about 95% and allincrements in between (for instance 11%, 25%, 55%, etc.).

Expanding upon this description, as shown in FIG. 4, a plurality ofadjacent slidable plates, 30, 32, 34 and 36, each having a partialopening 31, 33, 35 and 37 formed along one end, may be moved in thedirection of the arrows to vary the dimensions of the combined opening,orifice 39, between them, thus providing an adjustable cross-section die120A (for instance, for condyles 14 of FIG. 2) that the extrudate may beformed into. The partial openings 31, 33, 35 and 37 may each beconfigured as complex curves which when interconnected by specificpositioning of the slidable plates 30, 32, 34, 36 form, for instance,one or more cross-sections for the article to be extruded. Closing theplates relative to one another may form a somewhat smaller opening, forinstance extrudate forming the shaft 12, and further closing the platesrelative to one another may yield the cross-section shown in FIG. 3 as aconnecting portion 16. Accordingly, a continuous extrusion process maybe operated to yield articles of varying, non-uniform cross-sectionwhich are interconnected and may be separated for individual use later.

In one exemplary embodiment, as shown in FIG. 3, the extrudate mayinclude one or more shaped ends 14 with a cross-sectional dimension thatexceeds the cross-sectional dimension of another portion 16, 20 of saidextrudate wherein said one or more shaped ends 14 includes a pluralityof projecting surfaces. Such shaped end may be a bulbous shape, such ascondyle.

FIG. 5 illustrates the plates of die 120A in a position of being nearlytotally closed together to form an opening 39A from which the extrudatemay form the connecting portion of the dog chew 16. While FIGS. 4 and 5illustrate 4 interacting slidable plates, any number may be used, thegreater the number, the finer the detail of the features of the exteriorof the extrudate. It is further contemplated that the plates maycooperate in other the linear sliding fashion and that they may rotaterelative to one another, in iris-fashion, or some combination of rotaryand linear interaction. FIG. 7 illustrates the use of 4 adjacent plates52, 54, 56, 58 that interact on a rotary basis by rotating around pivotpoints 50 (note arrows). Each plate includes a complex curved edge 51,53, 55, 57 which cooperate when properly positioned relative to oneanother to form the cross-section 59 of die 120C which can produce anextrudate with the shape of the condyle of FIG. 3.

In a related embodiment, the die may be rotated around the extrudate asit emerges to cause the detailed features such as the condyles to beformed in a non-linear fashion relative to the longitudinal axis of thedog chew. In other words, the extrudate may be formed with a twist byrotating the die around the longitudinal axis of the extrudate. Seeelliptical arrow in FIG. 1. This may provide an even greater variety ofextruded non-uniform shapes.

In another related embodiment, an extrusion die may include a pluralityof orifices from which extrudate may be extruded, for instance 2, andthe die rotated relative to the streams E₄, E₅ of extrudate to form the“twisted” dog chew 516 as shown in FIG. 15. In other words, the dies maybe rotated around a plane located between the dies. It is furthercontemplated that E₄ and E₅ may have different compositions, and/orproperties to provide variety in the chew toy.

In a another exemplary embodiment, the adjustable die 120B may comprisea flexible member in the form of a ring or a tube 42 that can bedeformed into various shapes by locally applying pressure to one or moreareas on the periphery of the ring or tube. FIG. 6 illustrates a ring ortube member 42 preferably formed of a relatively heat resistant andflexible plastic or rubber that can withstand the temperaturesencountered in the extrusion of starch-based compositions. A pluralityof stroking members 46 may be located around the periphery of the ring,the stroking members capable of extension and retraction such that suchextension and or retraction may cause the ring, or tube, to change shapeand vary the shape of the extrudate being forced through it. Thestroking members may be attached to the ring or tube 42 so that outwarddistortion of the round shape may take place, as well as inwarddisplacement.

In the case of a tube, the stroking members may include elongated rodsor blades (not shown) that run along the length of the tube to deformthe tube substantially along its entire length. In a related embodiment,the stroking members may be configured to vary the cross-section of theopening along the length of the tube such that the cross-sectional shapeof the extrudate is gradually reduced from the entry point of theextrudate into the tube to the exit point where the final shape isconfigured, and accordingly may reduce any sharp increase in backpressure or overworking of the melt. While shown in FIG. 6 as round, theoriginal cross-section of the ring or tube 42 may be any shape thatallows the desired cross-section of the extrudate to be formed,including combinations of geometric shapes and complex curves including,for instance, the shape of the condyle of the dog chew of FIG. 2.Preferably, the ring or tube may include one or more stabilizers 44 toaid in controlling the deformation of the original shape.

The stroking members 46 may be in the form of pneumatic or hydrauliccylinders with variable strokes to cause the ring or tube to locallychange shape. The stroking distance and order may be programmed to bevaried as the extrudate is being forced through the die 120B.

In a related embodiment, the ring or tube 42 of FIG. 6 may be acted uponfrom the outside by the sliding plates illustrated in FIGS. 4, 5 and 7(instead of the stroking members) to deform the ring and cause the ringto be shaped into the desired orifice for the extrudate. This may be ofuse when the viscosity of the extrudate is low enough to cause sealingproblems between the adjacent sliding plates.

In another exemplary embodiment, an extrusion die 120D (see FIG. 8) maybe configured to form an orifice 60 for a starch-based melt at theoutput of an extruder, the orifice of any geometric shape desired for ananimal chew or pet toy. Portions 62 of the periphery 61 of the orifice60 may be displaced to manipulate the shape of the orifice, and theshape of the melt that is forced through the orifice. FIG. 8 illustratesone means of displacement which includes protruding portions 62 whichmay be varied in depth of protrusion by threaded sections 64. It iscontemplated that the die could also have movable blade portions. As themelt is forced through the orifice 60 it may be desirable to vary thedepth of one or more of the protrusions 62 to form grooves, orundulations, or bumps in the periphery of the extrudate. The protrudingportion may be moved by motorized, pneumatic or hydraulic means and themeans may be programmable.

In addition, the die and/or the extrudate may be twisted relative to oneanother to form the features on the extrudate in a spiral fashion (seeelliptical arrow in FIG. 1). The die can be rotated by attaching a chainor belt driven by a motor. The extrudate may be twisted by attaching apuller and then rotating the puller around the extrudate to impart atwisting force. Accordingly, an extrudate with external featuresincluding a twist to such may be provided.

In a related embodiment, the extrudate from die 120D may be directedinto a tube having a pattern of spiral grooves or protrusions, so thatat some point in the cooling of the extrudate, a relatively small twistmay be imparted to the extrudate, as opposed to externally rotating thedie or extrudate.

It is contemplated that individual dog chews of a given non-uniformshape may be cut from a continuous extrudate using rotating knifeblades, a guillotine, hot wire, or the like. In one exemplaryembodiment, the extrudate may be cut using a “gang cutter” with aplurality of blades, the cutter reciprocally traveling with and againstthe direction of travel of the extrudate such that it severs a pluralityof connecting portions at once and in so doing, does not significantlyaffect the rate of extrusion. In other words, 2 or 10 or 20 chew toys,for instance, may be cut at the same time from the extrudate using acutter with a plurality of spaced apart blades. Accordingly, the rate ofextrusion may be effected by only about 5% or about 10%.

It is also contemplated that the extruder feeding the shape-forming diemay include an accumulator so that changes in throughput of theextrudate caused by the variance in shape of the die may be accommodatedwithout substantial effect on the quality of the melt in the barrel, orso that intermittent output may be possible. The accumulator may bepositioned at a location upstream of the die wherein the melt isconveyed through the extruder and into the accumulator and then throughthe die.

In another exemplary embodiment, a dog chew or animal toy may be formedinto a three dimensional shape by providing extrudates from a pluralityof extrusion dies and combining such to form multiple lobes of a dogchew. “Lobe” or “lobed” as used herein refers to a rounded projectionthat extends from another shape, such as a four leaf clover has fourlobes.

FIG. 9A illustrates a dog chew 80 formed by combining two “comma-shaped”extrudates E_(A), Ec from two separate but identical dies (see FIG. 10)in a shaping die and cutting the product to length. FIG. 9B illustratesthe addition of a third extrudate E_(B) of similar cross-section fed toan adjusted shaping die to yield a different, 3-lobed shape 82.

FIG. 10 illustrates a schematic configuration for providing such lobedshapes, including a plurality of extruders 210, 220, 230 each with aprofile die 212, 222, 232. Consistent with FIG. 9A, extrudates E_(A) andE_(C) may be formed to the desired shape in dies 210, 230 and thoseextrudates combined in shaping die 242 while the melts are still capableof being shaped and adhered together. This may then produce, forinstance, an extrudate E_(D) having the profile as shown in FIG. 9A andwhen cut to length, form a shaped dog chew. By adding a third extrudateE_(B) from extruder 220 and die 222, and adjusting the shape of thecombining die 242, a shape 82 having a third lobe E_(B) as shown in FIG.9B may be manufactured as part of a continuous manufacturing process.

In a related embodiment, dissimilar shaped extrudates may be combined toform other dog chews of varying shape. FIG. 9C illustrates thecombination of two similar extrudates E_(A1) and E_(C1) having curvedprofiles that may be combined in a shaping die and cut to length to forma “V” or “U”-shaped dog chew 84. The addition of a heart-shaped lobe,extrudate E_(B1), provides a different shape 86, as shown in FIG. 9D.

By intermittent processing of the third extrudate through the third die,different shapes of combined extrudate may be provided as two and thenthree streams may be combined.

In another exemplary embodiment to provide dog chews or animal toys withnon-uniform, three dimensional shapes via extrusion, a starch-basededible composition may be formed into an extrudate by forcing the meltthrough an extrusion die and directly thereafter placing the extrudatebetween matched tooling to form the desired shape. The tooling may besuch that the chews/toys are separated as part of the forming process ora connecting portion (see 16 in FIG. 2) may be formed connectingadjacent shapes such that a continuous stream of chews/toys are formed.In this manner, the process may be continuous.

FIG. 11 illustrates one exemplary embodiment of a device for directlyforming the extrudate into a desired shape on a continuous basis.Interacting wheels 300, 302 may be provided having a plurality of matingcavities 320 placed or machined into the outer periphery of the wheels300, 302, the cavities 320 each comprising one half of the shape of thedog chew of FIG. 2 (for instance, see FIG. 1 where a section has beentaken along line 11-11 longitudinally along the chew). As the extrudate304 exits the extrusion die (note left arrow in FIG. 11), it is passedbetween the wheels 300, 302 and formed to shape by the matching cavities320. The matching cavities 320 comprise complementary shapes which whenmatched together by positioning of the interacting wheels form a moldset having a combined cavity with the shape of, for instance, the dogchew of FIG. 2. One or more cutting blades 306 may be provided on one orboth wheels 300, 302 which severs the extrudate 304 as it passes betweenthe wheels.

FIG. 11A is an enlarged side view of one of the matching cavity portionsof wheel 300 of FIG. 11 and illustrates one of the half cavities 320that may match a complementary cavity of wheel 302 such that when thecavities are forced together by the interaction of the wheels, anarticle having the shape of the combined cavities (for instance the dogchew of FIG. 2), may be formed.

In a related exemplary embodiment, the lower wheel 302 shown in FIG. 11may be replaced with a stationary surface and as the extrudate 304 exitsthe extrusion die (note left arrow in FIG. 11), it is passed between theupper wheel 300 and the stationary surface and formed to shape by thecavity 320. In such a process, the dog chew 10 may be formed with aconstant profile, such as flat, on that lower surface. It is furthercontemplated that the stationary surface may be concave and the lowersurface of the dog chew may then include a convex or curved surface.

FIG. 12 is a side view of a similar apparatus for forming elongatedshaped dog chews comprising a pair of cooperating belts 400, 402, whichare equipped with a series of matched cavities 420 along their surface.The belts 400, 402 may be stretched between rollers 408. As theextrudate 404 is fed between the belts (see left arrow), the matchedcavities are closed together to form a combined cavity of the desiredshape and the extrudate is shaped within the matched cavities 420. Theoutput may be, for instance, a dog chew 10 having the shape of thatshown in FIG. 2.

It is contemplated that complementary knife blades may be placedappropriately along the belts of FIG. 12 to sever the dog chews intosegments including one or more dog chews. In addition, it iscontemplated that connecting portions 16 may be formed between adjacentdog chews by the placement of connecting slots between adjacentcavities, or that no slots may be present and individual, separatedchews may be formed by the matched cavities.

In yet another exemplary embodiment, the extrusion die may be movedrelative to a molding surface to form non-uniform, three dimensionalshaped dog chews. FIG. 13 is a schematic representation of a workstation for extruding a melt of extrudate onto a surface by feeding themelt to a die whose position is controlled by a guiding apparatus, suchas a multi-axis robot, x-y table or the like. The device may beprogrammed to lay the extrudate in a defined pattern on the surface of amolding table or may be programmed to distribute a given quantity ofextrudate into a mold cavity placed on the table. The extruder 100 likethat shown in FIG. 1 may include a plurality of heating zones 112, 114,116, 118 and an extrusion die 120. The extrusion die 120 may beconnected to the end of the arm 502 of a robot 500 by a flexiblecoupling 506 capable of delivering the melt to the robot and capable ofsome flexing to allow the robot head 504 to move in a predeterminedpattern to deliver the extrudate E to a molding surface 520. A controlunit 508 for the robot 500 provides signals to vary the position of thehead vs. the molding surface, and therefore the location of theextrudate E emanating from the head.

In addition, it is contemplated that the extrusion head 504 may bestationary and that the molding surface 520 may be moved in crosswise,lengthwise and vertical planes (“X”, “Y” and “Z”) directions relative tothe head to manipulate an extrudate E from the die into a complex shape(for instance a pretzel shape, a word or phrase in cursive 510, etc.

In another related embodiment, see FIG. 13A, the molding surface 520 maycomprise a first mold cavity 530 into which a log of extrudate ofpredetermined size and weight may be distributed by the robot 500. Amatching second mold cavity (not shown) may then be positioned over thefirst cavity to form a closed cavity space for a shaped article, such asa dog chew.

In a still further related embodiment, the extrudate E from the robothead 504 (FIG. 13), may be delivered in a fashion to build shapes by theselective addition of successive passes by the robot head such that, forinstance, a dog chew shape may be built up. As shown in FIG. 14A, twoparallel passes of extrudate E₁ and E₂ may be laid on a molding surface520 such that the passes are in contact along their length and whencooled adhere to one another to form dog chew 512. The ends 92 and 94may be formed by pausing the lengthwise travel of the robot 500temporarily to provide an accumulation of extrudate E, for instance atthe ends of the chew.

FIG. 14B illustrates another shape for a dog chew 514 that may be formedby rotating the robot head 504 in a loop, followed by a relativelystraight line of extrudate, followed by another loop to form a centerportion E3 and two knuckle-like larger end portions 96 and 98.

It is further contemplated that the adjustable dies of FIGS. 4, 6, 7 and8 may be combined into the robotic workstation of FIG. 13 or to producethe multiple streams of extrudate of FIG. 10 to produce non-uniformextrudates that may be combined together in a shaping die or may bedelivered to a molding surface by a multi-axis robot. In that exemplaryembodiment, the flexible coupling 506 may act as an accumulator tocompensate for changes in throughput as the die orifice dimensions areadjusted and minimize any over shearing of the melt in the extruderbarrel.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method for forming chew toys of selected shape from ediblecompositions by extrusion comprising the steps of: providing an extruderincluding a barrel and a die having an adjustable orifice capable ofproviding a variety of cross-sectional dimensions; providing anextrudable composition comprising edible resin and water; introducingsaid composition to said barrel and subjecting said composition to shearand heat to form a melt; conveying said melt through said orifice whilevarying the cross-section dimensions of said orifice to form anextrudate having thickness dimensions that vary along its length whereinthe water content of said composition is sufficient to provide that saidcomposition can be varied in cross-section when conveyed through saidorifice with variation in said orifice cross-sectional dimension.
 2. Themethod of claim 1 wherein said water content of said composition that issufficient to provide that said composition can be varied incross-section when conveyed through said orifice is in the range of 10%by weight to 30% by weight.
 3. The method of claim 2 wherein said watercontent is in the range of 10% by weight to 20% by weight.
 4. The methodof claim 1 wherein said water content is in the range of 15% by weightto 20% by weight.
 5. The method of claim 1 wherein said extruderprovides a shear rate of 1 sec⁻¹ to 5000 sec⁻¹.
 6. The method of claim 1wherein said formed chew toys include a connecting portion and varyingof the cross-section dimensions of said orifice comprises varying saidorifice cross-section to provide a connecting portion between aplurality of chew toys.
 7. The method of claim 6 wherein said formedchew toy has a largest cross-sectional dimension and said connectingportion has a cross sectional dimension that is less than or equal to10% of said chew toy largest cross-sectional dimension.
 8. The method ofclaim 1 including an accumulator positioned at a location prior to saiddie wherein said melt conveys through said extruder and into saidaccumulator and then into said die.
 9. The method of claim 1 whereinsaid extrudate exiting said die is cut to length to form chew toys. 10.The method of claim 1 wherein said formed chew toys include a pluralityof connecting portions between said chew toys and the method furtherincludes simultaneously cutting said plurality of connecting portions toprovide a plurality of formed chew toys.
 11. The method of claim 10wherein said rate of conveying of said melt through said orifice is at aselected rate of output and said step of simultaneously cutting saidplurality of connecting portions does not substantially reduce saidselected rate of output.
 12. The method of claim 11 wherein saidselected rate of output is not reduced by more than 10%.
 13. The methodof claim 12 wherein said selected rate of output is not reduced by morethan 5%.
 14. The method of claim 1 wherein said dimensions of said dieare adjusted to form connecting portions intermittently in saidextrudate, said connecting portions capable of breaking after saidextrudate is cooled to form chew toys.
 15. The method of claim 1 whereinsaid die having an adjustable orifice comprises a plurality of adjacentslidable interacting plates, said plates each having a shaped partialopening along one edge, the partial openings of said edges of saidplates at least partially coinciding to provide one or more desiredcross-sections for said extrudate to be shaped by.
 16. The method ofclaim 15 wherein said plurality of plates interact in a linear fashionto form said desired cross-sections.
 17. The method of claim 15 whereinsaid plurality of plates interact in a rotary fashion to form saiddesired cross-sections.
 18. The method of claim 1 wherein said extrudateincludes one or more shaped ends with a cross-sectional dimension thatexceeds the cross-sectional dimension of another portion of saidextrudate wherein said one or more shaped ends includes a plurality ofprojecting surfaces.
 19. The method of claim 1 wherein said die includesa flexible ring or tube having an outer periphery and a plurality ofstroking members engage said outer periphery and movement of saidstoking members relative to said extrudate to cause said extrudate to beshaped.
 20. The method of claim 19 wherein said stroking memberscomprise a plurality of adjacent interacting plates, said plates eachhaving a shaped partial opening along one edge, the partial openings ofsaid edges of said plates engaging said periphery of said ring or tubeto provide a one or more desired shapes to said extrudate.
 21. Themethod of claim 19 wherein said ring comprises rubber or plastic. 22.The method of claim 1 wherein said die is rotated around said extrudateas said extrudate exits said die.
 23. The method of claim 1 wherein saiddie includes a segmented periphery and one or more of said segments isdisplaced into said orifice.
 24. The method of claim 1 further includinga second extrusion die spaced apart from said first adjustable die andextruding a second extrudate parallel to said first extrudate whereinsaid first and second dies are rotated around a plane located betweensaid dies to form a twisted extrudate.
 25. The method of claim 1 whereinsaid extrudable composition includes one or more of cellulose, glycerin,a nutraceutical, an enzyme, a co-enzyme, gluten and rawhide.
 26. Themethod of claim 1 wherein said extrudable composition includes one ormore of the following additives; vitamin, mineral, herb, surfactant,emulsifier, humectant, flavorant, colorant, yeast, attractant andcalcium carbonate.
 27. The method of claim 1 wherein said edible resincomprises starch that has not seen a prior thermal molding history. 28.The method of claim 26 wherein at least about 0.1-50% of the vitamins,minerals and herbs are not thermally degraded by subjecting saidcomposition to said shear and heat to form a melt.
 29. A method forforming chew toys of selected shape from an edible composition byextrusion, comprising the steps of: providing a first extruder, a secondextruder and a third extruder, wherein said first extruder includes afirst profile die, said second extruder includes a second profile dieand said third extruder includes a third profile die; providing a firstedible composition to said first extruder and a second ediblecomposition to said second extruder and a third edible composition tosaid third extruder; processing said first and second compositionsthrough said first and second extruders including through said first andsecond profile dies to form first and second extrudates which are thenjoined to one another in a shaping die, the shaping die having anopening substantially the same shape as the combined shapes of the firstand second profile dies; processing said third composition through saidthird extruder including through said third profile die to form a thirdextrudate; intermittently joining said third extrudate with saidcombined first and second extrudates in a second shaping die, the secondshaping die having an opening substantially the same shape as thecombined shapes of the first and second and third profile dies.
 30. Themethod of claim 29 wherein said profile dies are all of the same shape.31. The method of claim 29 wherein two of said profile dies are of thesame shape and the third die is of a shape that is complementary to thecombination of said first and second dies.
 32. A method for forming chewtoys of selected shape from edible compositions by extrusion, comprisingthe steps of: providing an extruder including a barrel and a die;providing an extrudable composition comprising an edible composition andwater; introducing said composition to said barrel and subjecting saidcomposition to shear and heat to form a melt; conveying said meltthrough said die to form an extrudate; passing said extrudate betweencooperating mold cavities having complementary shapes which form theshape of said chew toy while said extrudate is at a temperature andmoisture level which allows said extrudate to form within saidcooperating mold cavities; and forming said extrudate into the shape ofa chew toy.
 33. The method of claim 32 wherein said water content ofsaid extrudate that is passed between said cooperating mold cavities isat a level of 10% by weight to 30% by weight.
 34. The method of claim 32wherein said water content of said extrudate that is passed between saidcooperating mold cavities is at a level of 10̂% by weight to 20% byweight.
 35. The method of claim 32 wherein said water content of saidextrudate that is passed between said cooperating mold cavities is at alevel of 15% by weight to 20% by weight.
 36. The method of claim 32wherein said cooperating cavities reside in the outer periphery of apair of interacting wheels, wherein said wheels are rotated as saidextrudate is passed between said wheels such that said cooperatingcavities align with one another to form the shape of a chew toy.
 37. Themethod of claim 32 wherein said cooperating cavities reside in the outerperiphery of a pair of conveyor belts, wherein said belts are moved incoordination as said extrudate is passed between said belts such thatsaid cooperating cavities align with one another to form the shape of achew toy.
 38. The method of claim 32 wherein said extrudate is severedinto separate chew toys by said cooperating cavities.
 39. A method forforming chew toys of selected shape from edible compositions byextrusion, comprising the steps of: providing an extruder including abarrel and a die; providing an extrudable composition comprising anedible composition and water; introducing said composition to saidbarrel and subjecting said composition to shear and heat to form a melt;conveying said melt through said die to form an extrudate; providing asurface to receive said extrudate; guiding said die over said surface ina predetermined pattern to position said extrudate on said surface insaid predetermined pattern.
 40. The method of claim 39 wherein saidguiding is provided by a programmable multi-axis robot.
 41. The methodof claim 39 wherein said surface comprises a mold cavity and apredetermined length or volume of said extrudate may be deposited insaid mold cavity.
 42. The method of claim 39 wherein said die comprisesa die having an adjustable orifice capable of providing a variety ofcross-sectional dimensions to said extrudate.
 43. The method of claim 39wherein said predetermined pattern comprises forming relatively thickercross-sections of extrudate by pausing the movement of said die relativeto said surface.
 44. The method of claim 39 wherein said predeterminedpattern comprises forming relatively thicker cross-sections of extrudateby moving said die in a loop relative to said surface.
 45. The method ofclaim 39 wherein said extrudate is guided along parallel paths such thattwo or more portions of said extrudate lie in contact with one anotheralong at least a portion of the parallel paths to build up successivethicknesses of extrudate which adhere together when cooled.